Methods for cooling computers and electronics

ABSTRACT

An exemplary method may comprise thermally coupling a network of cooling lines to each of a plurality of heat exchangers in a cooling system. The method may also comprise providing a first connection from a network of cooling lines to a first fluid source and a second connection from the network of cooling lines to a second fluid source for configuring the network of cooling lines in different states. The method may also comprise delivering cooling fluid through the network of cooling lines to each of the plurality of heat exchangers both when the network of cooling lines is connected only to the first fluid source and when the network of cooling lines is connected to both the first and second fluid sources.

This application claims priority to co-owned U.S. Provisional PatentApplication No. 60/796,259 for “Flexible Redundant Cooling For ComputerSystems” of Belady, et al., filed Apr. 28, 2006, and is acontinuation/divisional of co-owned U.S. patent application Ser. No.11/673,410 for “Cooling Systems and Methods” of Belady, et al., filedFeb. 9, 2007 and claiming priority to the '259 provisional patentapplication, each hereby incorporated by reference in its entirety asthough fully set forth herein.

BACKGROUND

Electronic data centers including multiple computer systems (e.g.,rack-mounted servers) and other electronic devices are becoming moredensely packed to provide more computing power while at the same timeconsuming less physical space. Accordingly, heat dissipation continuesto be a concern. If not properly dissipated, heat generated duringoperation can shorten the life span of various components and/orgenerally result in poor performance.

Various thermal management systems are available for computer systemsand other electronic devices, and typically include a heat sink and/or acooling fan. The heat sink is positioned adjacent the electroniccomponents generating the most heat (e.g., the processor) to absorbheat. A cooling fan may be positioned to blow air across the heat sinkand out an opening formed through the computer housing to dissipate heatinto the surrounding environment. The use of water-cooled systems isalso being explored. However, if the heat sink, cooling fan, and/orwater supply fails or is otherwise taken offline (e.g., for maintenancepurposes), one or more of the computer systems and/or other electronicdevices may need to be taken offline as well to prevent overheatinguntil the cooling system can be returned to an operational state. Anysuch shutdown, even a partial shutdown, can have a far reaching negativeimpact and therefore is considered undesirable.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS 1 a and 1 b are top and side views, respectively, of an exemplarycooling system as it may be implemented in a rack-mount environment forserver computers.

FIGS. 2-4 are simplified views of exemplary embodiments of the coolingsystem showing primarily the network of cooling lines.

FIGS. 5 and 6 show alternative embodiments of a cooling system.

DETAILED DESCRIPTION

Briefly, cooling systems and methods may be implemented to dissipateheat during operation of various computing and electronic devices, suchas in the rack-mount environment commonly used by electronic datacenters. In an exemplary embodiment, the cooling systems and methodsinclude redundant fluid sources for cooling operations. Optionally, thecooling system may be configured for use with either single or multiplefluid sources. Where multiple fluid sources are used, if one of thefluid sources fails, is taken offline, or is otherwise unavailable, analternate fluid source may continue to provide sufficient cooling toprevent a partial or even complete shut down of the computing and/orother electronic devices.

FIGS. 1 a and 1 b are top and left-side views, respectively, of anexemplary cooling system 100 as it may be implemented in a rack-mountenvironment for server computers. Directional notations 105 a and 105 bare shown in FIGS. 1 a and 1 b, respectively, to help orient the reader.

Before continuing, it is noted that the rack-mount environment in FIGS.1 a and 1 b is shown only for purposes of illustration. The systems andmethods described herein are not limited to use with any particularphysical environment. Nor are the systems and methods limited to usewith any particular type of computers or other electronic devices.

In an exemplary embodiment, a rack-mount 110 may be implemented toarrange a plurality of computer systems (e.g., server computer 120mounted to physical structure or rack 109) and/or other electronicdevices such as storage, communications, and/or data processing devices(not shown). The rack-mount 110 may include an outer enclosure 130 withaccess door 135. The server computers are typically arranged within theenclosure 130 in a stacked relation relative to one another.Accordingly, only one server computer 120 is visible from the top viewshown in FIG. 1 a. Of course, a wide variety of other types ofrack-mounts are also commercially available. For example, largerrack-mounts enable the server computers to be arranged in a stackedrelation and a side-by-side relation relative to one another.

Each server computer 120 may include one or more processing units orprocessors, data storage, and/or memory. Each server computer 120 mayalso be operatively associated with other electronic components, suchas, communication and networking devices (routers, switches, hubs), anda wide variety of input/output (1/O) devices. These other electroniccomponents may also be arranged in the rack-mount 110.

During operation, the server computers and other electronic componentsmay generate heat. Accordingly, a cooling system 100 may be implementedto absorb and remove heat from the rack-mount 110. In an exemplaryembodiment, the cooling system 100 includes one or more heat exchangers140 a-d located near or adjacent the components generating the heat. Theheat exchangers 140 a-d function to absorb heat generated by the variousheat-generating components.

In an exemplary embodiment, the heat exchangers 140 a-d are made of athermally conductive material (e.g., metal or metal alloys, composites,ceramic, plastics, etc.) for quickly and efficiently absorbing heat fromthe surroundings and releasing it to a second medium (e.g., a fluidmedium such as water) flowing through the heat exchangers 140 a-d. It isnoted that there exist many different types of heat exchangers, and thesystems and methods described herein are not limited to any particulartype of heat exchangers 140 a-d. Optionally, the cooling system 100 mayalso include one or more cooling fans 160 a-d arranged to move orcirculate air in a closed loop between the server computer 120 and heatexchangers 140 a-d through ducting 150 a-d and out vent 170 a-d in thedirection generally illustrated by arrows 101-103.

It is noted that although four heat exchangers 140 a-d and cooling fans160 a-d are shown in FIG. 1 b, any number may be implemented. Indeed,there need not be a one-to-one correlation of heat exchangers to coolingfans. It is also noted that the location of the components may also vary(e.g., on the side next to the server computer 120 as shown, bottom,front, rear, or top). The specific implementation may depend on any of awide variety of different design considerations, such as, the heat beinggenerated, the desired cooling, and the surrounding environment, to nameonly a few examples.

As mentioned above, a cooling fluid (e.g., water) may be circulatedthrough the heat exchangers 140 a-d to remove heat. The cooling fluidmay be connected to one or more fluid source 180 (e.g., a building'swater supply), and provided to the heat exchangers 140 a-d via a networkof cooling lines 190. In an exemplary embodiment, the network of coolinglines 190 may be configured (or reconfigured) for use with either singleor multiple fluid sources. Such an implementation enables a productionand distribution of a single cooling system 100 which can be used inmore than one environment, thereby reducing costs.

In addition, the cooling system 100 may be operated in a redundant modeif it is configured for use with multiple fluid sources. That is, if oneof the fluid sources fails, is taken offline, or otherwise isunavailable, an alternate fluid source may continue to providesufficient cooling to continue operations (e.g., of one or more server120).

In an exemplary embodiment, power consumption may also be automaticallyreduced in the event that one or more of the fluid sources isunavailable. That is, operation of the heat-generating components isconstrained by the ability of the cooling system 100 to dissipate heat.In some circumstances, at least some of the components (e.g., criticalservers) may continue to operate at full power while power to othercomponents (e.g., to alternate, backup systems, or those executing lowpriority applications that are not business critical) is reduced or eventurned off to meet these constraints. In any event, the loss of a fluidsource for cooling operations does not result in a complete shut down.

It is noted that any of a wide variety of configurations of the coolingsystem 100 may be implemented to accomplish these and other advantages.Some examples of different configurations are discussed below withreference to FIGS. 2-6.

FIGS. 2-4 are simplified views of exemplary embodiments of the coolingsystem showing primarily the network of cooling lines (e.g., the networkof cooling lines 190 shown in FIG. 1 b). Other system components havebeen omitted or simplified in FIGS. 2-4 to better show differentconfigurations of the network of cooling lines,

FIG. 2 shows two configurations 200 and 200′ of a network of coolinglines 290 that may be implemented in the same cooling system (e.g.,cooling system 100 shown in FIGS. 1 a and 1 b). The network of coolinglines 290 may be connected to a single fluid source 280, as shown in thefirst configuration 200. The network of cooling lines 290 may also beconnected to dual fluid sources 280 and 281, as shown in the secondconfiguration 200′.

In the first configuration 200, the network of cooling lines 290 isconnected to a first fluid source 280 such that a cooling fluid maycirculate via fluid lines 291 a-d (delivery lines) and fluid lines 292a-d (return lines). The fluid lines 291 a-d and 292 a-d areinterconnected by junction boxes 295 a-d. Junction boxes 295 a-d alsoserve to connect the fluid lines to the heat exchangers (e.g., as can beseen in FIG. 1 b). Other embodiments are also contemplated whereinsubstitutions are made for the junction boxes.

The same cooling system may be configured (as illustrated by arrow 201)in the second configuration 200′ by removing the fluid lines 291 c(delivery line) and 292 c (return line) between junction boxes 295 b and295 c, and adding fluid line 291 e (delivery line) and fluid line 292 e(return line) between the second fluid source 281 and junction box 295d.

In the second configuration 200′, the cooling system is redundant. Thatis, if one of the fluid sources 280 or 281 is unavailable, operationsmay continue with each heat exchanger carrying a portion of the load.For purposes of illustration, the cooling system may be configured foroperation at full power when fluid is provided by both fluid sources 280and 281. But if one of the fluid sources 280 or 281 is unavailable, theoperations need only be reduced by 50% because each heat exchanger isstill able to dissipate 25% of the heat being generated where four heatexchanger are used. Other embodiments are also contemplated, e.g., sizedfor 200% capacity so that when one line fails, 100% of the load is stillmaintained.

FIG. 3 shows two configurations 300 and 300′ of a network of coolinglines 390 that may be implemented in the same cooling system (e.g.,cooling system 100 shown in FIGS. 1 a and 1 b). The network of coolinglines 390 may be connected to a single fluid source 380, as shown in thefirst configuration 300. The network of cooling lines 390 may also beconnected to dual fluid sources 380 and 381, as shown in the secondconfiguration 300′.

In the first configuration 300, the network of cooling lines 390 isconnected to a first fluid source 380 such that a cooling fluid maycirculate via fluid lines 391 a-d (delivery lines) and fluid lines 392a-d (return lines). The fluid lines 391 a-d and 392 a-d areinterconnected by junction boxes 395 a-d. Junction boxes 395 a-d alsoserve to connect the fluid lines to the heat exchangers (e.g., as can beseen in FIG. 1 b).

In addition, control valves 398 a and 398 b may be provided on fluidlines 391 c and 392 c, respectively. These may be open when the networkof cooling lines 390 is connected to only the first fluid source 380.The same cooling system may be configured (as illustrated by arrow 301)in the second configuration 300′ by closing these valves (the closedvalves are designated 398 a′ and 398 b′), and adding fluid line 391 e(delivery line) and fluid line 392 e (return line) between the secondfluid source 281 and junction box 295 d. Accordingly, the fluid lines391 c (delivery line) and 392 c (return line) do not need to be removedto configure the network of cooling lines 390 in the secondconfiguration 300′. Again, the cooling system is redundant in the secondconfiguration 300′, and there is only need for a single part numberwhere a valve is used to set the configuration during installation atthe customer site.

FIG. 4 shows two configurations 400 and 400′ of a network of coolinglines 490 that may be implemented in the same cooling system (e.g.,cooling system 100 shown in FIGS. 1 a and 1 b). The network of coolinglines 490 may be connected to a single fluid source 480, as shown in thefirst configuration 400. The network of cooling lines 490 may also beconnected to dual fluid sources 480 and 481, as shown in the secondconfiguration 400′.

In the first configuration 400, the network of cooling lines 490 isconnected to a first fluid source 480 such that a cooling fluid maycirculate via fluid lines 491 a-d (delivery lines) and fluid lines 492a-d (return lines). The fluid lines 491 a-d and 492 a-d areinterconnected by junction boxes 495 a-d. Junction boxes 495 a-d alsoserve to connect the fluid lines to the heat exchangers (e.g., as can beseen in FIG. 1 b).

Control valves 498 a-f may be operated to configure the network ofcooling lines 490 in the first configuration 400 by opening controlvalves 498 a-d and closing control valves 498 e and 498 f. Controlvalves 498 c-d and 498 e-f may be opened and control valves 498 a-bclosed to configure the cooling system in a second configuration 400′for connection to dual fluid source 480 and 481. Again, the coolingsystem is redundant in the second configuration 400′.

Also when the network of cooling lines 490 is in the secondconfiguration 400′, the control valves may be operated to reconfigurethe network of cooling lines 490 for a single fluid source in the eventone of the fluid sources 480 or 481 becomes unavailable duringoperation. In addition, if fluid source 481 is lost for example, thesystem senses this and shuts control valves 498 e-f and dynamicallyopens control valves 498 a-b so that so that no capacity is lost duringoperation and it is all done automatically (e.g., the system is selfaware as to whether there is one source or two so that it autoconfigures at installation, or auto reconfigures due to a failure).

FIGS. 5 and 6 show alternative embodiments of a cooling system. It isnoted that 500- and 600-series reference numbers are used in FIGS. 5 and6 to refer to corresponding elements of the embodiment of cooling system100 shown in FIG. 1 b, and may not be described again with reference tothe different embodiments of cooling systems shown in FIGS. 5 and 6.

FIG. 5 shows two configurations 500 and 500′ of the same cooling system.In the first configuration, the cooling system includes a single heatexchanger 540, at least one cooling fan (four cooling fans 560 a-d areshown), and ducting 550. The cooling system can be configured for in asecond configuration 500′ for dual fluid sources 580 and 581 by addinganother heat exchanger 540′.

In an exemplary embodiment, the heat exchangers 540 and 540′ areconfigured in series with all of the cooling fans 560 a-d. Such aconfiguration reduces the likelihood of a failure that cripples theentire system. In addition, the system is modular and may be upgraded inthe field to make it redundant for customers who may change theircooling configuration to redundant sources. Furthermore, the system canbe easily configured in the factory or can be configured duringinstallation by adding heat exchanger.

FIG. 6 shows two configurations 600 and 600′ of the same cooling system.Configurations 600 and 600′ are similar to the configurations shown inFIG. 5. In this embodiment, however, the cooling system is provided withoptional jumper lines 699 between the heat exchangers 640 and 640′.Accordingly, the same system can be configured without having to obtaina heat exchanger 640′ (e.g., after purchasing the cooling system).

It is noted that control valves (e.g., as shown in FIGS. 3 and 4) mayalso be implemented in the embodiments shown in FIG. 6. For example,static control valves, such as those shown in FIG. 3, may be implementedto open or close depending on the configuration 600 or 600′. inaddition, dynamic control valves, such as the servo controlled valvesshown in FIG. 4, may be implemented on lines 699 and 690 (for 680 and681). In this way the system may be automatically configured as afunction of the conditions sensed during installation or failure.

It should be appreciated that various exemplary embodiments of thecooling system shown (and other embodiments not shown) may bemanufactured and shipped for configuration as either a single or a dualfluid cooled system at the factory, and then configured at the customersite. When the cooling system is Configured for dual sources, it alsohas redundant cooling capacity.

It is noted that the exemplary embodiments discussed above are providedfor purposes of illustration. Still other embodiments are alsocontemplated. For example, fluid line failures may be detectedautomatically by the building monitoring system and/or with sensors(e.g., pressure, flow, temperature sensors) included as part of thecooling system itself, and/or control valves may be automaticallyopened/closed to support the building fluid supply conditions.

It is also noted that, although the systems and methods are describedwith reference to computer systems, in other exemplary embodiments, thecooling systems may be implemented for other electronic devices, suchas, e.g., peripheral devices for computers, video and audio equipment,etc.

In addition to the specific embodiments explicitly set forth herein,other aspects and embodiments will be apparent to those skilled in theart from consideration of the specification disclosed herein. It isintended that the specification and illustrated embodiments beconsidered as examples only.

1. A method comprising: thermally coupling a network of cooling lines toeach of a plurality of heat exchangers in a cooling system; providing afirst connection from a network of cooling lines to a first fluid sourceand a second connection from the network of cooling lines to a secondfluid source for configuring the network of cooling lines in differentstates; and delivering cooling fluid through the network of coolinglines to each of the plurality of heat exchangers both when the networkof cooling lines is connected only to the first fluid source and whenthe network of cooling lines is connected to both the first and secondfluid sources.
 2. The method of claim 1 further comprising configuringthe network of cooling lines for connection to a single fluid source. 3.The method of claim 1 further comprising configuring the network ofcooling lines for connection to a plurality of fluid sources.
 4. Themethod of claim 3 wherein configuring the network of cooling lines isvia at least one control valve.
 5. The method of claim 1 furthercomprising automatically closing at least one control valve if one ofthe fluid sources is unavailable.
 6. The method of claim 1 furthercomprising automatically sensing which of the at least one of the fluidsources is available/unavailable and automatically reconfiguring thenetwork of cooling lines.
 7. The method of claim 1 further comprisingconnecting/disconnecting at least two heat exchangers in the network ofcooling lines to one another based on available fluid sources.
 8. Themethod of claim 1 further comprising automatically adjusting power to atleast one heat-generating component based on heat-removal capacity ofthe cooling system as a result of a dynamic change in the heat-removalcapacity.
 9. A method for cooling computer systems and other electronicscomprising: providing a first and a second source for cooling fluids;positioning a plurality of heat exchangers to absorb heat duringoperation; making a first connection for the first fluid source andmaking a second connection for the second fluid source; and thermallyconnecting a network of cooling lines to each of the plurality of heatexchangers, the network of cooling lines fluidly connectable in threestates, wherein in a first state the network being coupled to the firstconnection, in a second state the network being coupled to the secondconnection, and in a third state the network being coupled to both thefirst connection and the second connection.
 10. The method of claim 9further comprising providing the network of cooling lines for redundantcooling if connected to both the first fluid source and the second fluidsource.
 11. The method of claim 9 further comprising configuring thenetwork of cooling lines to continue delivering cooling fluid to each ofthe plurality of heat exchangers even if one of the first fluid sourceor the second fluid source is unavailable.
 12. The method of claim 9further comprising providing a plurality of junction boxes and aplurality of jumper lines for configuring the network of cooling linesfor connection to at least one of the first fluid source and the secondfluid source.
 13. The method of claim 9 further comprising providing atleast one control valve for configuring the network of cooling lines forswitching between the first fluid source and the second fluid source.14. The method of claim 9 further comprising thermally coupling thenetwork of cooling lines in series to the plurality of heat exchangers.15. The cooling system of claim 9 further comprising thermally couplingthe network of cooling lines in parallel to the plurality of heatexchangers.
 16. The method of claim 9 further comprising providingjumper lines for connecting/disconnecting at least two of the pluralityof heat exchangers to one another based on the number of fluid sources.17. The method of claim 9 further comprising configuring the network ofcooling lines for use in a rack-mount environment for server computers.